# US 9,518,193 B2 · Coating processes using waterborne curable film-forming compositions containing polymers derived from natural gas raw materials

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- Number: US 9,518,193 B2
- Document ID: US9518193B2
- Status: Granted
- Kind: B2
- Application number: 14/164,676
- Filed: 2014-01-27
- Published: 2015-07-30
- Granted: 2016-12-13
- Earliest claimed: 2014-01-27
- Assignees: PPG Industries Ohio, Inc.
- Applicants: Ppg Industries Ohio, Inc.
- Inventors: Shanti Swarup; Kurt G Olson; John E Schwendeman; Leigh Ann Humbert; Kelly E Lutz; Carol Lynn Boggs
- Web page: https://patentgrep.com/patent/US9518193B2

## CPC

- C09D 133/12: Homopolymers or copolymers of methyl methacrylate
- B01J 13/14: Polymerisation; cross-linking
- B01J 13/206: {Hardening; drying}
- B01J 13/22: Coating
- B05D 1/36: Successively applying liquids or other fluent materials, e.g. without intermediate treatment
- B05D 3/0254: {After-treatment}
- B05D 7/14: to metal, e.g. car bodies (involving a chemical reaction between the metal and the coating C23)
- B05D 7/532: {the two layers being cured or baked together, i.e. wet on wet}
- C09B 67/009: {polymeric dispersing agent}
- C09B 67/0097: {Dye preparations of special physical nature; Tablets, films, extrusion, microcapsules, sheets, pads, bags with dyes}
- C09B 67/0098: {Organic pigments exhibiting interference colours, e.g. nacrous pigments}
- C09D 5/022: {Emulsions, e.g. oil in water}
- C09D 131/04: Homopolymers or copolymers of vinyl acetate
- C25D 13/00: Electrophoretic coating characterised by the process (C25D15/00 takes precedence; compositions for electrophoretic coating C09D5/44)
- B05D 7/542: {the two layers being cured or baked together}
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C09B: ORGANIC DYES OR CLOSELY-RELATED COMPOUNDS FOR PRODUCING DYES {, e.g. PIGMENTS}; MORDANTS; LAKES (fermentation or enzyme using processes to synthesise a desired chemical compound C12P)
- C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR

## Abstract

A method is provided for forming a composite coating on a substrate comprising: (A) applying a first coating composition to a surface of the substrate; and (B) applying a second coating composition to the first coating prior to substantially heating or curing the first coating. The first and/or second coating composition is a waterborne curable film-forming composition comprising: (a) an aqueous dispersion of internally crosslinked polymeric microparticles having a core-shell morphology and having reactive functional groups; and (b) a crosslinking agent. The core of the polymeric microparticles is prepared from a monomer mixture comprising at least 20 percent by weight of a monomer having the structure: wherein X is N or O; R is a linear or branched alkyl group having 1 to 18 carbon atoms, or R is bonded to X to form a 5- to 7-member ring.

## Claims

### Claim 1

A method for forming a composite coating on a substrate comprising:
(A) applying a first coating composition to at least a portion of a surface of the substrate; and
(B) applying a second coating composition to at least a portion of the first coating formed in step (A) prior to substantially heating or curing the first coating, to form a secondary coating thereon and yielding a composite coating; wherein the first and/or second coating composition is a waterborne curable film-forming composition comprising an aqueous dispersion of:
(a) internally crosslinked polymeric microparticles having a core-shell morphology and having reactive functional groups; and
(b) a crosslinking agent having functional groups reactive with functional groups on the polymeric microparticles;
wherein the core of the polymeric microparticles is prepared from a monomer mixture comprising at least 20 percent by weight of a monomer having the structure:
wherein X is N or O; R is a linear or branched alkyl group having 1 to 18 carbon atoms, or R is bonded to X to form a 5- to 7-member ring; based on the total weight of monomers in the monomer mixture.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first coating layer is applied over the substrate to yield a dry film thickness of 15 to 30 microns.

### Claim 3 (depends on 1)

The method according to claim 1, further comprising an initial step of forming an electrodeposited coating upon the surface of the substrate prior to applying the first coating composition of step (A), wherein the first coating composition is applied directly onto the electrodeposited coating.

### Claim 4 (depends on 1)

The method according to claim 1, further comprising: (C) holding the substrate at a temperature and for a time sufficient to substantially cure the composite coating after all coating layers have been applied to the substrate.

### Claim 5 (depends on 1)

The method of claim 1, further comprising: (C) applying a clear coating composition to at least a portion of the secondary coating applied in step (B) prior to substantially curing the secondary coating, to form a clear coating thereon.

### Claim 6 (depends on 5)

The method according to claim 5, further comprising: (D) holding the substrate at a temperature and for a time sufficient to substantially cure the composite coating after all coating layers have been applied to the substrate.

### Claim 7 (depends on 1)

The method of claim 1, wherein the first and second coating compositions are the same and each further comprises a colorant.

### Claim 8 (depends on 1)

The method of claim 1, wherein the second coating composition is the waterborne curable film-forming composition comprising:
(a) an aqueous dispersion of internally crosslinked polymeric microparticles having a core-shell morphology and having reactive functional groups; and
(b) a crosslinking agent having functional groups reactive with functional groups on the polymeric microparticles;
wherein the core of the polymeric microparticles is prepared from a monomer mixture comprising at least 20 percent by weight of a monomer having the following structure:
wherein X is N or O; R is a linear or branched alkyl group having 1 to 18 carbon atoms, or R is bonded to X to form a 5- to 7-member ring; and wherein the second coating composition further comprises a metallic effect colorant.

### Claim 9 (depends on 1)

The method of claim 1, wherein the monomer mixture used to prepare the core of the polymeric microparticles further comprises methyl methacrylate, butyl acrylate, and at least one monomer having two or more ethylenically unsaturated groups.

### Claim 10 (depends on 9)

The method of claim 9, wherein the monomer mixture used to prepare the core of the polymeric microparticles further comprises at least one hydroxy functional ethylenically unsaturated monomer.

### Claim 11 (depends on 9)

The method of claim 9, wherein the monomer mixture used to prepare the core of the polymeric microparticles is essentially free of styrene.

### Claim 12 (depends on 1)

The method of claim 1, wherein the monomer mixture used to prepare the shell of the polymeric microparticles comprises methyl methacrylate, butyl acrylate, at least one hydroxy functional ethylenically unsaturated monomer, and at least one acid functional ethylenically unsaturated monomer.

### Claim 13 (depends on 12)

The method of claim 12, wherein the monomer mixture used to prepare the shell of the polymeric microparticles comprises 25 to 35 percent by weight acid functional ethylenically unsaturated monomer.

### Claim 14 (depends on 12)

The method of claim 12, wherein the monomer mixture used to prepare the shell of the polymeric microparticles comprises 45 to 55 percent by weight hydroxy functional ethylenically unsaturated monomer.

### Claim 15 (depends on 1)

The method of claim 1, wherein the crosslinking agent comprises an aminoplast.

### Claim 16 (depends on 1)

The method of claim 1, wherein the waterborne curable film-forming composition has a resin solids content of 25 to 30 percent by weight, based on the total weight of resin solids in the curable film-forming composition.